EP1348534A1 - Process for the manufacturing of an optical reflector - Google Patents

Process for the manufacturing of an optical reflector Download PDF

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Publication number
EP1348534A1
EP1348534A1 EP03290608A EP03290608A EP1348534A1 EP 1348534 A1 EP1348534 A1 EP 1348534A1 EP 03290608 A EP03290608 A EP 03290608A EP 03290608 A EP03290608 A EP 03290608A EP 1348534 A1 EP1348534 A1 EP 1348534A1
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EP
European Patent Office
Prior art keywords
insert
face
reflective layer
mold
optical reflector
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
EP03290608A
Other languages
German (de)
French (fr)
Inventor
José c/o Valeo Vision Ortiz
Laurent c/o Valeo Vision Meister
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Valeo Vision SAS
Original Assignee
Valeo Vision SAS
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Valeo Vision SAS filed Critical Valeo Vision SAS
Publication of EP1348534A1 publication Critical patent/EP1348534A1/en
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00596—Mirrors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
    • B29C45/14811—Multilayered articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/1703—Introducing an auxiliary fluid into the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
    • B29C2045/14237—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure the inserts being deformed or preformed outside the mould or mould cavity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
    • B29K2995/003—Reflective
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2011/00—Optical elements, e.g. lenses, prisms
    • B29L2011/0083—Reflectors

Definitions

  • the invention provides a method for manufacturing a optical reflector.
  • Such optical reflectors are generally used in the automotive industry to make lights or headlamps for fitting out motor vehicles.
  • the reflecting face of an optical reflector is generally concave and its generator is designed to obtain a beam of light of determined conformation.
  • optical reflectors by molding a thermoplastic material, then coating the face internal concave functional by a reflective layer which is for example based on aluminum.
  • the surface of the part obtained has irregularities and roughness which, even after coating with the reflective layer, affect the quality of the light beam.
  • the primer has generally tend to soften these edges, so that it harms him also the quality of the light beam.
  • Document EP-A-0.727.677 proposes to realize the face reflective on an insert made from a sheet of thermoformed plastic material, to overmold the body of the optical reflector on faces of the insert which are not intended to form the light beam, then to coat the surface concave functional by the reflective layer.
  • thermoforming of the plastic sheet makes it possible to have very good reflection surfaces which are not altered during the molding of the body. However, in the case of a complex reflection surface, some areas are sometimes difficult to access, so that the entire surface of reflection is not fully covered sufficiently by the reflective layer.
  • the invention proposes a process of the type described above, characterized in that the deposition step of the reflective layer is prior to the forming step.
  • FIG. 7 shows an optical reflector 10 which is a hollow element made in two parts. It has a concave insert 12 which is made from a sheet of material thermoformed plastic 14, which has an internal face concave front 18 which is covered with a reflective layer 20 in particular based on aluminum, and a rear external face convex 22.
  • the optical reflector 10 also comprises a body 16, which gives reflector 10 its structural rigidity, which is molded around the rear face 22 of the insert 12.
  • FIGS 1 to 5 show the successive stages of a process for producing the optical reflector 10, in accordance with the invention.
  • a first front face 14a of the sheet 14 is coated with a reflective layer 20 based on aluminum or other material reflecting, by any known method, for example by deposition under vacuum or by another method such as “PVD” deposition (Physical Vapor Deposition) or in “PECVD” (Plasma Enhanced Chemical Vapor Deposition).
  • PVD Physical Vapor Deposition
  • PECVD Plasma Enhanced Chemical Vapor Deposition
  • a second step in the process shown in Figures 1 to 3 consists in making the insert 12 by forming the sheet 14.
  • the matrix 24 is in relief, and the sheet 14 is therefore positioned with its first face 14a facing the matrix 24 so that the front face 18 is concave.
  • the matrix 24 is hollow and the sheet 14 is then positioned with its first face 14a opposite the matrix 24.
  • the sheet 14 is made of thermoplastic material, for example polycarbonate.
  • thermoplastic material for example polycarbonate.
  • the latter is heated and then applied to the matrix 24. So that the sheet 14 fully matches the shape of the matrix 24, a vacuum is made between the sheet 14 and the matrix 24, so as to press the sheet against die 24.
  • thermoforming can be obtained by other technologies well known in the art.
  • the insert 12 is placed inside a mold 28 for overmolding the body 16 around the rear face 22 of insert 12.
  • the mold 28 is formed of a fixed block 30 which has a protuberance 32 which is of complementary shape to that of the front face 18 of insert 12, which allows on the one hand to position the insert 12 in the mold 28 and, on the other hand, to prevent the insert 12 from deforming during molding.
  • the mold 28 is also formed of a movable block 34 comprising an imprint which defines a volume 36, with the face rear 22 of the insert 12, when the mold 28 is closed.
  • Volume 36 is then filled with a product thermoplastic to form the body 16 of the reflector 10.
  • the injected product is a mixture of a thermoplastic material and of a gas in liquid form. When the product is inside the volume 36, the gas expands to form a foam.
  • a product thermoplastic to form the body 16 of the reflector 10.
  • the assembly is then removed from the mold and forms the reflector 10.
  • the material injected into the mold can not be in the form of a foam.
  • the coating of the sheet 14 can be carried out before it is cut, that is to say when it is still on a reel.
  • the deposition of the reflective layer 20 can then be carried out continuously, resulting in significant time savings compared to art front where each optical reflector was coated one after the other of the reflective layer.
  • a very important advantage of the invention is that it allows to deposit reflective layers on materials whose surface condition is not excellent: even with initial surface of medium quality, we obtain after deposit of the reflective layer of optical quality reflectors quite satisfactory. We can thus overcome aspect constraints that we could have with the layer deposition processes standards. Therefore, one can use for the material constituting the reflector body of polymeric materials with a significant level of expenses. These charges can be introduced either for cost reasons or as an expense of reinforcing the polymeric material. With the invention, the rate the charge in the polymer can be at least 10% by weight, and possibly up to 60 to 70% by weight of the total body weight of the reflector, while obtaining a level of surface quality sufficient optics after deposition of the reflective coating.
  • polycarbonate polycarbonate
  • polyamide thermoplastic or thermosetting polyethylene
  • the charges can be organic or mineral, for example based on carbon, calcium carbonates, and can be in the form of particles, fibers ...

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Ophthalmology & Optometry (AREA)
  • Optical Elements Other Than Lenses (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)

Abstract

A reflector is made by forming an insert, molding the body of the insert and depositing a reflective layer on the concave surface of the insert. Deposition of the reflective layer (20) takes place before the molding stage. An Independent claim is included for the reflector made as described.

Description

L'invention propose un procédé pour la fabrication d'un réflecteur optique.The invention provides a method for manufacturing a optical reflector.

L'invention propose plus particulièrement un procédé de fabrication d'un réflecteur optique creux du type qui comporte un corps arrière surmoulé autour de la face externe arrière convexe d'un insert avant dont la face interne avant concave est recouverte (notamment au moins partiellement) d'un revêtement réfléchissant, le procédé comportant :

  • une étape de réalisation de l'insert par formage ;
  • une étape de surmoulage du corps sur l'insert ; et
  • une étape de dépôt de la couche réfléchissante sur la face avant concave de l'insert (ou sur au moins une partie de ladite face).
The invention more particularly provides a method of manufacturing a hollow optical reflector of the type which comprises a rear body overmolded around the convex rear external face of a front insert whose concave internal front face is covered (in particular at least partially) a reflective coating, the method comprising:
  • a step of producing the insert by forming;
  • a step of overmolding the body on the insert; and
  • a step of depositing the reflective layer on the concave front face of the insert (or on at least part of said face).

De tels réflecteurs optiques sont généralement utilisés dans l'industrie automobile pour fabriquer des feux ou des projecteurs pour équiper les véhicules automobiles.Such optical reflectors are generally used in the automotive industry to make lights or headlamps for fitting out motor vehicles.

La face réfléchissante d'un réflecteur optique est généralement concave et sa génératrice est conçue de sorte à obtenir un faisceau de lumière de conformation déterminée.The reflecting face of an optical reflector is generally concave and its generator is designed to obtain a beam of light of determined conformation.

Il est connu de réaliser les réflecteurs optiques par moulage d'un matériau thermoplastique, puis de revêtir la face concave interne fonctionnelle par une couche réfléchissante qui est par exemple à base d'aluminium.It is known to produce optical reflectors by molding a thermoplastic material, then coating the face internal concave functional by a reflective layer which is for example based on aluminum.

Cependant, lorsque la surface du moule est dégradée, ou bien lorsqu'elle n'est pas à une température optimale, la surface de la pièce obtenue présente des irrégularités et des aspérités qui, même après le revêtement par la couche réfléchissante, nuisent à la qualité du faisceau lumineux.However, when the mold surface is degraded, or well when it's not at an optimal temperature the surface of the part obtained has irregularities and roughness which, even after coating with the reflective layer, affect the quality of the light beam.

Pour remédier à ce problème, il a été proposé d'utiliser un apprêt qui colmate les différentes aspérités de la surface de la pièce moulée pour former une surface lisse et qui est ensuite revêtue par la couche réfléchissante. To remedy this problem, it has been proposed to use a primer that clogs the various roughness of the surface of the molded part to form a smooth surface which is then coated with the reflective layer.

Cependant, lorsque la face réfléchissante est de forme complexe, et qu'elle comporte des arêtes vives, l'apprêt a généralement tendance à adoucir ces arêtes, de sorte qu'il nuit lui aussi à la qualité du faisceau lumineux.However, when the reflective face is shaped complex, and with sharp edges, the primer has generally tend to soften these edges, so that it harms him also the quality of the light beam.

Le document EP-A-0.727.677 propose de réaliser la face réfléchissante sur un insert réalisé à partir d'une feuille de matériau plastique thermoformé, de surmouler le corps du réflecteur optique sur des faces de l'insert qui ne sont pas destinées à former le faisceau lumineux, puis de revêtir la surface concave fonctionnelle par la couche réfléchissante.Document EP-A-0.727.677 proposes to realize the face reflective on an insert made from a sheet of thermoformed plastic material, to overmold the body of the optical reflector on faces of the insert which are not intended to form the light beam, then to coat the surface concave functional by the reflective layer.

Le thermoformage de la feuille plastique permet d'avoir des surfaces de réflexion de très bonne qualité et qui ne sont pas altérées lors du moulage du corps. Cependant, dans le cas d'une surface de réflexion complexe, certaines zones sont parfois difficilement accessibles, de sorte que toute la surface de réflexion n'est pas entièrement recouverte de manière suffisante par la couche réfléchissante.The thermoforming of the plastic sheet makes it possible to have very good reflection surfaces which are not altered during the molding of the body. However, in the case of a complex reflection surface, some areas are sometimes difficult to access, so that the entire surface of reflection is not fully covered sufficiently by the reflective layer.

Pour remédier à ces inconvénients, l'invention propose un procédé du type décrit précédemment, caractérisé en ce que l'étape de dépôt de la couche réfléchissante est antérieure à l'étape de formage.To remedy these drawbacks, the invention proposes a process of the type described above, characterized in that the deposition step of the reflective layer is prior to the forming step.

Selon d'autres caractéristiques de l'invention :

  • l'étape de formage de l'insert est une étape de thermoformage d'une feuille ;
  • l'étape de moulage consiste à injecter dans un moule un mélange qui est composé du matériau constitutif du corps et d'un gaz sous forme liquide et qui est susceptible de former une mousse dans le moule ;
  • lors de l'étape de moulage, la face avant de l'insert est en appui sur une protubérance d'un bloc du moule qui est de forme complémentaire à celle de la face avant.
According to other characteristics of the invention:
  • the step of forming the insert is a step of thermoforming a sheet;
  • the molding step consists in injecting into a mold a mixture which is composed of the constituent material of the body and of a gas in liquid form and which is capable of forming a foam in the mold;
  • during the molding step, the front face of the insert is supported on a protuberance of a block of the mold which is of shape complementary to that of the front face.

D'autres caractéristiques et avantages de l'invention apparaítront à la lecture de la description détaillée qui suit pour la compréhension de laquelle on se reportera aux figures annexées parmi lesquelles :

  • les figures 1 à 3 sont des vues schématiques en perspective qui représentent les étapes successives de l'étape de thermoformage de l'insert à partir d'une feuille thermoplastique, conforme à l'invention ;
  • les figures 4 et 5 sont des sections longitudinales et transversales de l'insert et du moule représentant les étapes successives de l'étape de surmoulage du corps conforme à l'invention ;
  • la figure 6 est une section longitudinale et à plus grande échelle du réflecteur optique obtenu par le procédé conforme à l'invention ; et
  • la figure 7 est une vue en perspective de dessous du réflecteur optique obtenu après l'étape de surmoulage représentée aux figures 4 et 5.
Other characteristics and advantages of the invention will appear on reading the detailed description which follows for the understanding of which reference will be made to the appended figures among which:
  • Figures 1 to 3 are schematic perspective views which show the successive steps of the step of thermoforming the insert from a thermoplastic sheet, according to the invention;
  • Figures 4 and 5 are longitudinal and cross sections of the insert and the mold showing the successive stages of the body molding step according to the invention;
  • Figure 6 is a longitudinal section and on a larger scale of the optical reflector obtained by the method according to the invention; and
  • FIG. 7 is a perspective view from below of the optical reflector obtained after the overmolding step shown in FIGS. 4 and 5.

Pour la description de l'invention, on adoptera à titre non limitatif les orientations verticale, longitudinale et transversale selon les repères V1, L1, T1 et V2, L2, T2 indiqués aux figures.For the description of the invention, the following will not be adopted limiting the vertical, longitudinal and transverse orientations according to the references V1, L1, T1 and V2, L2, T2 indicated in the figures.

On adoptera aussi la direction d'arrière en avant comme étant la direction longitudinale et de droite à gauche en se reportant à la figure 4.We will also adopt the direction from back to front as being the longitudinal direction and from right to left in referring to figure 4.

Dans la description qui va suivre, des éléments identiques, similaires ou analogues seront désignés par les mêmes chiffres de référence.In the description which follows, identical elements, similar or analogous will be designated by the same numbers reference.

On a représenté à la figure 7 un réflecteur optique 10 qui est un élément creux réalisé en deux parties. Il comporte un insert concave 12 qui est réalisé à partir d'une feuille de matériau plastique 14 thermoformée, et qui comporte une face interne avant concave 18 qui est recouverte d'une couche réfléchissante 20 notamment à base d'aluminium, et une face externe arrière convexe 22. FIG. 7 shows an optical reflector 10 which is a hollow element made in two parts. It has a concave insert 12 which is made from a sheet of material thermoformed plastic 14, which has an internal face concave front 18 which is covered with a reflective layer 20 in particular based on aluminum, and a rear external face convex 22.

Le réflecteur optique 10 comporte aussi un corps 16, qui procure au réflecteur 10 sa rigidité structurelle, et qui est surmoulé autour de la face arrière 22 de l'insert 12.The optical reflector 10 also comprises a body 16, which gives reflector 10 its structural rigidity, which is molded around the rear face 22 of the insert 12.

Les figures 1 à 5 représentent les étapes successives d'un procédé de réalisation du réflecteur optique 10, conforme à l'invention.Figures 1 to 5 show the successive stages of a process for producing the optical reflector 10, in accordance with the invention.

Selon une première étape du procédé non représentée, une première face avant 14a de la feuille 14 est revêtue d'une couche réfléchissante 20 à base d'aluminium ou d'autre matériau réfléchissant, par toute méthode connue, par exemple par dépôt sous vide ou par une autre méthode telle que le dépôt en "PVD" (Physical Vapor Deposition) ou en "PECVD" (Plasma Enhanced Chemical Vapor Deposition).According to a first step of the process not shown, a first front face 14a of the sheet 14 is coated with a reflective layer 20 based on aluminum or other material reflecting, by any known method, for example by deposition under vacuum or by another method such as "PVD" deposition (Physical Vapor Deposition) or in "PECVD" (Plasma Enhanced Chemical Vapor Deposition).

Une deuxième étape du procédé représentée aux figures 1 à 3 consiste à réaliser l'insert 12 par formage de la feuille 14.A second step in the process shown in Figures 1 to 3 consists in making the insert 12 by forming the sheet 14.

Pour cela on utilise une matrice 24 dont la forme est déterminée pour que la première face 14a de la feuille 14 prenne la forme de la matrice 24 pour former les premières faces 18 de l'insert 12.For this we use a matrix 24 whose shape is determined so that the first face 14a of the sheet 14 takes the shape of the matrix 24 to form the first faces 18 of insert 12.

Ici, la matrice 24 est en relief, et la feuille 14 est donc positionnée avec sa première face 14a en vis-à-vis de la matrice 24 de sorte que la face avant 18 soit concave.Here, the matrix 24 is in relief, and the sheet 14 is therefore positioned with its first face 14a facing the matrix 24 so that the front face 18 is concave.

Inversement, et selon une variante non représentée, la matrice 24 est creuse et la feuille 14 est alors positionnée avec sa première face 14a opposée à la matrice 24.Conversely, and according to a variant not shown, the matrix 24 is hollow and the sheet 14 is then positioned with its first face 14a opposite the matrix 24.

La feuille 14 est en matériau thermoplastique, par exemple en polycarbonate. Ainsi, pour le formage de la feuille 14, celle-ci est chauffée puis appliquée sur la matrice 24. Pour que la feuille 14 épouse totalement la forme de la matrice 24, un vide est réalisé entre la feuille 14 et la matrice 24, de manière à plaquer la feuille contre la matrice 24.The sheet 14 is made of thermoplastic material, for example polycarbonate. Thus, for the forming of the sheet 14, the latter is heated and then applied to the matrix 24. So that the sheet 14 fully matches the shape of the matrix 24, a vacuum is made between the sheet 14 and the matrix 24, so as to press the sheet against die 24.

En variante, sans sortir du cadre de l'invention, le thermoformage peur être obtenu par d'autres technologies bien connues de la technique. Alternatively, without departing from the scope of the invention, the thermoforming can be obtained by other technologies well known in the art.

On obtient alors l'insert 12 qui, comme représenté à la figure 3, est démoulé après refroidissement, et ses bords 26 sont découpés.We then obtain the insert 12 which, as shown in the Figure 3, is removed from the mold after cooling, and its edges 26 are cut.

Selon une troisième étape du procédé, représentée aux figures 4 et 5, l'insert 12 est placée à l'intérieur d'un moule 28 pour le surmoulage du corps 16 autour de la face arrière 22 de l'insert 12.According to a third step of the process, represented in Figures 4 and 5, the insert 12 is placed inside a mold 28 for overmolding the body 16 around the rear face 22 of insert 12.

Le moule 28 est formé d'un bloc fixe 30 qui comporte une protubérance 32 qui est de forme complémentaire de celle de la face avant 18 de l'insert 12, ce qui permet d'une part de positionner l'insert 12 dans le moule 28 et, d'autre part, d'empêcher que l'insert 12 ne se déforme lors du moulage.The mold 28 is formed of a fixed block 30 which has a protuberance 32 which is of complementary shape to that of the front face 18 of insert 12, which allows on the one hand to position the insert 12 in the mold 28 and, on the other hand, to prevent the insert 12 from deforming during molding.

Le moule 28 est aussi formé d'un bloc mobile 34 comportant une empreinte qui définit un volume 36, avec la face arrière 22 de l'insert 12, lorsque le moule 28 est fermé.The mold 28 is also formed of a movable block 34 comprising an imprint which defines a volume 36, with the face rear 22 of the insert 12, when the mold 28 is closed.

Le volume 36 est ensuite rempli par un produit thermoplastique pour former le corps 16 du réflecteur 10. Le produit injecté est un mélange d'un matériau thermoplastique et d'un gaz sous forme liquide. Quand le produit est à l'intérieur du volume 36, le gaz se détend, pour former une mousse. Un tel produit et sa mise en oeuvre sont par exemple décrits dans le document EP-A-1.040.158.Volume 36 is then filled with a product thermoplastic to form the body 16 of the reflector 10. The injected product is a mixture of a thermoplastic material and of a gas in liquid form. When the product is inside the volume 36, the gas expands to form a foam. Such product and its implementation are for example described in the document EP-A-1.040.158.

La formation d'une telle mousse permet de réduire la quantité de matériau utilisée.The formation of such foam reduces the amount of material used.

Lorsque la mousse formant le corps 16 a refroidi, c'est-à-dire qu'il s'est rigidifié, l'ensemble est alors démoulé et forme le réflecteur 10.When the foam forming the body 16 has cooled, that is to say that it has stiffened, the assembly is then removed from the mold and forms the reflector 10.

Il sera aussi compris que des inversions mécaniques simples peuvent constituer des variantes de réalisation de l'invention. Par exemple, le matériau injecté dans le moule peut ne pas se présenter sous la forme d'une mousse.It will also be understood that mechanical inversions simple may constitute alternative embodiments of the invention. For example, the material injected into the mold can not be in the form of a foam.

De plus, le revêtement de la feuille 14 peut être réalisé avant sa découpe, c'est-à-dire lorsqu'elle est encore en bobine. Le dépôt de la couche réfléchissante 20 peut alors être effectué en continu, d'où un gain de temps important par rapport à l'art antérieur où chaque réflecteur optique était revêtu l'un après l'autre de la couche réfléchissante.In addition, the coating of the sheet 14 can be carried out before it is cut, that is to say when it is still on a reel. The deposition of the reflective layer 20 can then be carried out continuously, resulting in significant time savings compared to art front where each optical reflector was coated one after the other of the reflective layer.

Un avantage très important de l'invention est qu'elle permet de déposer des couches réfléchissantes sur des matériaux dont l'état de surface n'est pas excellent: même avec des états de surface initiaux de qualité moyenne, on obtient après dépôt de la couche réfléchissante des réflecteurs de qualité optique tout à fait satisfaisante. On peut ainsi s'affranchir des contraintes d'aspect que l'on pouvait avoir avec les procédés de dépôt de couches standards. Par conséquent, on peut utiliser pour le matériau constitutif du corps du réflecteur des matériaux polymères avec un niveau significatif en charges. Ces charges peuvent être introduites soit pour des raisons de coût, soit en tant que charge de renforcement de la matière polymère. Avec l'invention, le taux de charge dans le polymère peut être d'au moins 10% en poids, et éventuellement jusqu'à 60 à 70% en poids du poids total du corps du réflecteur, tout en obtenant un niveau de qualité de surface optique suffisant après dépôt du revêtement réfléchissant. Pour constituer le polymère du réflecteur, on peut par exemple choisir parmi un ou plusieurs des polymères suivants : polycarbonate, polyamide, polyéthylène thermoplastique ou thermodurcissable, de préférence chargé comme mentionné plus haut. Les charges peuvent être organiques ou minérales, par exemple à base de carbone, de carbonates de calcium, et peuvent être sous forme de particules, de fibres ...A very important advantage of the invention is that it allows to deposit reflective layers on materials whose surface condition is not excellent: even with initial surface of medium quality, we obtain after deposit of the reflective layer of optical quality reflectors quite satisfactory. We can thus overcome aspect constraints that we could have with the layer deposition processes standards. Therefore, one can use for the material constituting the reflector body of polymeric materials with a significant level of expenses. These charges can be introduced either for cost reasons or as an expense of reinforcing the polymeric material. With the invention, the rate the charge in the polymer can be at least 10% by weight, and possibly up to 60 to 70% by weight of the total body weight of the reflector, while obtaining a level of surface quality sufficient optics after deposition of the reflective coating. For constitute the polymer of the reflector, one can for example choose from one or more of the following polymers: polycarbonate, polyamide, thermoplastic or thermosetting polyethylene, preferably loaded as mentioned above. The charges can be organic or mineral, for example based on carbon, calcium carbonates, and can be in the form of particles, fibers ...

Claims (7)

Procédé de fabrication d'un réflecteur optique (10) creux du type qui comporte un corps arrière (16) surmoulé autour de la face externe arrière convexe (22) d'un insert avant (12) dont la face interne avant concave (18) est recouverte d'une couche réfléchissante (20), le procédé comportant : une étape de réalisation de l'insert (12) par formage ; une étape de surmoulage du corps (16) sur l'insert (12) ; et une étape de dépôt de la couche réfléchissante (20) sur la face avant concave (18) de l'insert (12) ;    caractérisé en ce que l'étape de dépôt de la couche réfléchissante (20)est antérieure à l'étape de formage.Method for manufacturing a hollow optical reflector (10) of the type which comprises a rear body (16) molded around the convex rear external face (22) of a front insert (12) whose concave front internal face (18) is covered with a reflective layer (20), the method comprising: a step of producing the insert (12) by forming; a step of overmolding the body (16) on the insert (12); and a step of depositing the reflective layer (20) on the concave front face (18) of the insert (12); characterized in that the step of depositing the reflective layer (20) is prior to the forming step. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que l'étape de formage de l'insert (12) est une étape de thermoformage d'une feuille (14).Method according to any one of the preceding claims, characterized in that the step of forming the insert (12) is a step of thermoforming a sheet (14). Procédé selon la revendication précédente, caractérisé en ce que l'étape de moulage consiste à injecter dans un moule (28) un mélange qui est composé du matériau constitutif du corps (16) et d'un gaz sous forme liquide et qui est susceptible de former une mousse dans le moule (28).Method according to the preceding claim, characterized in that the molding step consists in injecting into a mold (28) a mixture which is composed of the material constituting the body (16) and of a gas in liquid form and which is capable of form a foam in the mold (28). Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que lors de l'étape de moulage, la face avant (18) de l'insert (12) est en appui sur une protubérance (32) d'un bloc (30) du moule (28) qui est de forme complémentaire à celle de la face avant (18).Method according to any one of the preceding claims, characterized in that during the molding step, the front face (18) of the insert (12) is supported on a protuberance (32) of a block (30 ) of the mold (28) which is of shape complementary to that of the front face (18). Réflecteur optique obtenu selon le procédé conforme à l'une au moins des revendications précédentes, caractérisé en ce que le matériau constitutif du corps dudit réflecteur est à base de polymère(s) avec un taux de charge d'au moins 10% en poids, notamment compris entre 10 et 70% en poids. Optical reflector obtained according to the method according to at least one of the preceding claims, characterized in that the material constituting the body of said reflector is based on polymer (s) with a charge rate of at least 10% by weight, in particular between 10 and 70% by weight. Dispositif d'éclairage et/ou de signalisation automobile comportant au moins un réflecteur optique selon la revendication 5.Automotive lighting and / or signaling device comprising at least one optical reflector according to claim 5. véhicule automobile équipé d'au moins un dispositif selon la revendication 6.motor vehicle equipped with at least one device according to claim 6.
EP03290608A 2002-03-29 2003-03-12 Process for the manufacturing of an optical reflector Ceased EP1348534A1 (en)

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FR0204171 2002-03-29
FR0204171A FR2837741B1 (en) 2002-03-29 2002-03-29 METHOD FOR MANUFACTURING AN OPTICAL REFLECTOR

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US10252460B1 (en) * 2014-09-15 2019-04-09 Lockheed Martin Corporation Method of forming an optical element using an additive manufactured component, and related devices, components, and systems
JP2020003705A (en) * 2018-06-29 2020-01-09 日機装株式会社 Optical component, manufacturing method of optical component, and light irradiation device

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WO1999032544A1 (en) * 1997-12-19 1999-07-01 Trexel, Inc. Microcellular foam extrusion/blow molding process and article made thereby
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EP0727677A1 (en) * 1994-08-03 1996-08-21 Polyplastics Co. Ltd. Production method of light-reflecting component and light-reflecting component produced by the method
WO1999032544A1 (en) * 1997-12-19 1999-07-01 Trexel, Inc. Microcellular foam extrusion/blow molding process and article made thereby
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EP2327528A1 (en) * 2009-11-30 2011-06-01 Cie Automotive, S.A. Moulding device for preparing surface decorated resin articles and method for preparing such articles

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FR2837741B1 (en) 2004-06-11
FR2837741A1 (en) 2003-10-03
US20030184865A1 (en) 2003-10-02
US6919037B2 (en) 2005-07-19

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